Armored crate apparatus and manufacturing system

ABSTRACT

An armored enclosure apparatus and system of manufacturing thereof is described. The apparatus is equipped with an enclosure substrate, at least one opening panel, and a durable exterior coating. The exterior coating is preferably molded to the exterior of the enclosure substrate, resulting in a fortified container suitable for storage, transport, and delivery of sensitive, fragile, valuable, and otherwise damage-prone items. An interior of the enclosure substrate may also be equipped with a molded coating configured to further protect contents of the enclosure. Thickness of the exterior coating may vary in accordance with the size of the enclosure, and the contents.

This application is a non-provisional application of provisional patentapplication number 62/656,659, filed on Apr. 12, 2018, and priority isclaimed thereto.

FIELD OF THE PRESENT INVENTION

The present invention relates to the field of shipping, materialhandling, protection, and logistics, and more specifically relates to anarmored enclosure apparatus, and manufacturing system thereof, whichfacilitates safe transport and storage of fragile and/or expensive itemssuch as sensitive electronics, luxury furniture, valuable minerals/gems,moisture-sensitive items, any delicate goods, etc.

BACKGROUND OF THE PRESENT INVENTION

There are several different means by which items may be transported viaair or ground freight. While many conventional items are adequatelytransported in cardboard or similarly structured disposable boxes, it isinevitable that the contents of some boxes will be damaged. Damage oftenoccurs during transit, as well as within a storage warehouse whileawaiting shipment. Packaged products can be damaged if they are impactedfrom a forklift, from a warehouse storage rack, or can even be damagedduring loading to a truck. Likewise, contents of crates and boxes can bedamaged during delivery, as they may be impacted while within thestorage bay of a delivery truck upon taking a sharp turn. In some cases,traditional packaging and their respective contents may be destroyedupon falling from the truck or forklift, or from the hands of deliverypersonnel. This is especially true for packages containing sensitiveitems, such as computer servers, luxury furniture, sensitive vehiclecomponents, photography equipment, other volatile electronics, or anydelicate products.

If there were a way by which such items could be more sufficientlyprotected during storage, transit, and delivery, damaged merchandise andprized possessions would be far less susceptible to irreparable damage.

Some solutions to instances of property damage during transit presentlyexist on the market. For example, Pelican™ (and similar companies)manufactures durable, fortified plastic and/or metal containers suitablefor specific valuable items, such as firearms, photography equipment,precious minerals, and other delicate items. While effective, containerssuch as these are prohibitively expensive, and are generally designedfor a singular purpose—the transport of a specific item, encased withinan internal form-fitting foam of the container. This foam is usuallycustom-sized for the contents of the container, adding to the expense.Additionally, containers such as these are generally purchased and usedby the owner of the item, and are therefore purchased after the owner isin possession of the fragile item. In accordance with their high cost,containers such as these are often equipped with a lifetime warranty,and are designed to be used hundreds of times without failing.

However, containers such as these are not suitable for the conventionaltransport of fragile/sensitive goods. Unfortunately, the fact remainsthat simple foam inserts of cardboard boxes, in addition to bubble wrap(or similar air-based filler material) and/or packing peanuts, remainthe most commonly used (and most cost effective) means by which fragileitems are transported. These protective elements often fail.

Thus, there is a need for a new form of armored shipping apparatussuitable for use by both individuals and corporations, to more safelytransport valuable, sensitive, and otherwise fragile goods in a costeffective manner. Such an apparatus preferably employs a crate, which isthen coated in a durable, shock absorbing, semi-elastic compound, whicheffectively protects the substrate (lending to improved protection andre-use of the crate) as well as its contents during storage, loading,transit, and delivery.

SUMMARY OF THE PRESENT INVENTION

This Summary of the Invention is provided to introduce a selection ofconcepts in a simplified form that are further described below in theDetailed Description. This Summary is not intended to identify keyfeatures or essential features of the claimed subject matter, nor is itintended to be used to limit the scope of the claimed subject matter.

The present invention is an armored enclosure and process ofmanufacturing thereof, which is configured to protect contents fromdamage during storage and transit, as well as prevent contamination ofthe contents by infestation, liquids, corrosives, and other conventionalcontaminants. The armor of the armored crate is an exterior coatingpreferably composed of Polyurea or Polyurethane (or a blend). Theexterior coating is applied as at least one layer of protection, and isconfigured to both seal the substrate from contaminants, as well as toprovide shock absorption, increasing the structural integrity ofenclosure. The present invention is preferably equipped with at leastone opening panel which is configured to be removed by the end user toretrieve the protected contents of the apparatus.

Some embodiments of the present invention are equipped with an interiorcoating similar to that of the exterior coating. The interior coating,in addition to the exterior coating, provides additional protection ofthe contents during storage, transport, and delivery.

It is envisioned that the enclosure substrate of the present inventionis preferably composed of one or more of the following components:bamboo, hemp, cellular PVC, plastic, vinyl, straw composite, paper,metal, fiberboard, fiberglass, fiberglass-faced gypsum panels,corrugated plastic, corrugated cardboard, carbon fiber, mesh, orcomposites. Exterior coating of the present invention is present at athickness ranging from 0.015 inches to two inches in order to adequatelyincrease the structural integrity of the enclosure assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form a partof the specification, illustrate the present invention and, togetherwith the description, further serve to explain the principles of theinvention and to enable a person skilled in the pertinent art to makeand use the invention.

The present invention will be better understood with reference to theappended drawing sheets, wherein:

FIG. 1 depicts an environmental view of the preferred embodiment of theapparatus of the present invention as seen from the front and side.

FIG. 2 exhibits a front and side view of the raw substrate of theapparatus of the present invention.

FIG. 3 shows a cutaway view of the apparatus of the present invention,showing a portion of the enclosure as raw substrate, and a portion ofthe enclosure equipped with coating.

FIG. 4 depicts an environmental view of the apparatus of the presentinvention, showing the opening panel in the open position, and equippedwith contents.

FIG. 5 shows a cross-sectional view of the exterior coating layer of thepresent invention, depicted atop the enclosure substrate.

FIG. 6 exhibits a flow chart detailing the manufacturing process of theapparatus of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present specification discloses one or more embodiments thatincorporate the features of the invention. The disclosed embodiment(s)merely exemplify the invention. The scope of the invention is notlimited to the disclosed embodiment(s). The invention is defined by theclaims appended hereto.

References in the specification to “one embodiment,” “an embodiment,”“an example embodiment,” etc., indicate that the embodiment describedmay include a particular feature, structure, or characteristic, butevery embodiment may not necessarily include the particular feature,structure or characteristic. Moreover, such phrases are not necessarilyreferring to the same embodiment, Further, when a particular feature,structure, or characteristic is described in connection with anembodiment, it is submitted that it is within the knowledge of oneskilled in the art to effect such feature, structure, or characteristicin connection with other embodiments whether or not explicitlydescribed.

The present invention is an armored enclosure (20) apparatus suitablefor use during the transport and storage of fragile or otherwisesensitive goods. The apparatus amounts to an enclosure for storing goodsto protect them from theft, leakage, exposure, and damage due to naturalor physical forces and contamination.

The apparatus of the present invention is equipped with an enclosuresubstrate (40), which is preferably composed of hemp, straw composite,bamboo, cellular PVC, metal, fiberglass, fiberglass-faced gypsum panels,corrugated plastic, corrugated cardboard, carbon fiber, mesh, or similarsturdy planar material. The enclosure substrate (40) is fashioned intopanels of varying thickness, which is assembled as an enclosure equippedwith an interior (50). The interior (50) may be equipped with, orwithout dividers, amounting to a perimeter shell as shown in FIG. 2 andFIG. 3. Foam may also be used as the enclosure substrate (40).

Additionally, one or more sides of the enclosure substrate (40) is anopening panel (30), which is preferably removable in order to deposit orretrieve contents (60) housed within the apparatus of the presentinvention. The opening panel (30) may be removed via prying, or may beconfigured to pivot, slide, or retract to act as a hinged or slidingdoor.

The exterior of the enclosure substrate (40) is equipped with anexterior coating (10), the coating is preferably composed of a layer(s)of Polyurea or Polyurethane (or a blend). The exterior coating (10) ispreferably present at a thickness of 0.015 to two inches in order toincrease the structural integrity of the enclosure substrate (40). Theexterior coating (10) of the present invention is configured to allowmore volatile and/or fragile goods to be stored within the presentinvention. The exterior coating (10) is therefore a non-corrosive,liquid-proof contamination barrier.

Similarly, an interior (50) of the present invention may also beequipped with an interior coating (70). The interior coating (70)preferably has a thickness between 0.015 inches and two inches, and ispresent in order to further increase the structural integrity of theenclosure substrate (40). In such instances, the present invention maybe used to transport even more volatile goods, including liquids, andadds a non-corrosive, infestation-proofing, and contaminate-proofingbarrier internally. The interior coating (70) employed in someembodiments of the present invention may also be food-safe to facilitatetransport of fragile food items.

The process by which the apparatus of the present invention ispreferably constructed, as depicted in FIG. 6, is preferably as follows:

1. First, a conventional fortified crate is manufactured with at leastone panel of the conventional six panels configured to pivot or beremoved to facilitate depositing or retrieval of stored goods. Theremovable or pivoting opening panel is temporarily closed. (100) Inembodiments of the present invention equipped with an interior coating,the interior coating is first applied to the entire assembly orindividual panels composing the enclosure.

2. Next, with the enclosure closed but without the opening panelattached, at least one layer (though preferably several) of Polyurea orPolyurethane (or a blend of the two) is applied to the exterior of theenclosure substrate, forming a cohesive barrier surrounding allcomponents of the exterior of the enclosure substrate. (110) Thelayer(s) are preferably applied via a spray or molding process by whichthe Polyurea or Polyurethane is chemically bonded to the enclosuresubstrate (regardless of the material composition of the enclosuresubstrate).

3. Then, after the Polyurea or Polyurethane has dried and hardened, thearmored enclosure may accept hardware items followed by contents forstorage and transport. (120)

4. Finally, after the armored enclosure is equipped with content(goods), the opening panel(s) are secured, and the armored enclosure issealed (with or without a watertight gasket) until it reaches the endconsumer at a final destination. (130)

Additionally, some embodiments of the present invention may be equippedwith one or more mechanical fasteners, such as a bolt action fastener,screws, at least one clasp, lever, and/or similar security device (suchas a padlock, keyed lock, or electrical lock) to ensure that the atleast one opening panel (30) remains in position securely during storageand transport.

It should be understood that the armored enclosure (20) of the presentinvention may be one of an assortment of infinitely ranging sizesconfigured to store sizable goods, some of which requiring materialhandling equipment such as forklifts, pallet jacks, lift gates, and/oroverhead lifting device. The size of the enclosure substrate need notlimit the scope of the present invention.

Having illustrated the present invention, it should be understood thatvarious adjustments and versions might be implemented without venturingaway from the essence of the present invention. Further, it should beunderstood that the present invention is not solely limited to theinvention as described in the embodiments above, but further comprisesany and all embodiments within the scope of this application.

The foregoing descriptions of specific embodiments of the presentinvention have been presented for purposes of illustration anddescription. They are not intended to be exhaustive or to limit thepresent invention to the precise forms disclosed, and obviously manymodifications and variations are possible in light of the aboveteaching. The exemplary embodiment was chosen and described in order tobest explain the principles of the present invention and its practicalapplication, to thereby enable others skilled in the art to best utilizethe present invention and various embodiments with various modificationsas are suited to the particular use contemplated.

I claim:
 1. An armored crate apparatus comprising: an enclosure; anenclosure substrate, said enclosure substrate composed of at least oneof the following: hemp, straw composite, bamboo, cellular PVC, metal,fiberglass, fiberglass-faced gypsum panels, corrugated plastic,corrugated cardboard, carbon fiber, and mesh; wherein said enclosureencompasses said enclosure substrate; an interior, said interior presentwithin said enclosure substrate; an opening panel, said opening paneldisposed as one of multiple panels of said enclosure; and an exteriorcoating, said exterior coating disposed atop said enclosure substrate.2. The apparatus of claim 1, wherein said exterior coating is composedof at least one layer of polyurethane.
 3. The apparatus of claim 1,wherein said exterior coating is non-corrosive.
 4. The apparatus ofclaim 1, wherein said exterior coating is a liquid-proof contaminationbarrier.
 5. The apparatus of claim 1, further comprising: an interiorcoating, said interior coating disposed within said interior, on anunderside of said enclosure substrate.
 6. The apparatus of claim 5,wherein said interior coating is food-safe.
 7. The apparatus of claim 5,wherein said interior coating is an infestation-proofing barrier.
 8. Theapparatus of claim 5, wherein said interior coating is acontaminate-proofing barrier.
 9. The apparatus of claim 1, wherein saidopening panel is configured to pivot up and away from said enclosure,facilitating access to said interior.
 10. The apparatus of claim 1,wherein said opening panel is configured to be pried off of saidenclosure to facilitate access to said interior.
 11. The apparatus ofclaim 1, wherein said exterior coating is composed of at least one layerof polyurea.
 12. The apparatus of claim 5, wherein said exterior coatingis composed of at least one layer of polyurethane.
 13. The apparatus ofclaim 5, wherein said exterior coating is composed of at least one layerof polyurea.
 14. The apparatus of claim 5, wherein said exterior coatingis a liquid-proof contamination barrier.
 15. The apparatus of claim 5,wherein said opening panel is configured to pivot away from saidenclosure, facilitating access to said interior.
 16. The apparatus ofclaim 5, wherein said opening panel is configured to be pried off ofsaid enclosure to facilitate access to said interior.
 17. An armoredcrate apparatus comprising: an enclosure; an enclosure substrate, saidenclosure substrate composed of at least one of the following: hemp,straw composite, bamboo, cellular PVC, metal, fiberglass,fiberglass-faced gypsum panels, corrugated plastic, corrugatedcardboard, carbon fiber, and composite; wherein said enclosureencompasses said enclosure substrate; an interior, said interior presentwithin said enclosure substrate; an opening panel, said opening paneldisposed as one of multiple panels of said enclosure; and an exteriorcoating, said exterior coating disposed atop said enclosure substrate.